Split Bending Mold for Insulated Busbar Precision
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Solution Overview
Problem
Conventional bending machines face challenges in producing high-quality bent parts with small bending radii and short leg lengths due to material thickening and twisting issues, which can lead to inaccuracies and potential jamming, especially when dealing with insulated busbars in complex installation environments.
Innovation Solution
A bending machine equipped with a split bending mold that allows for adjustable clear height of the circumferential groove, minimizing twisting by ensuring a form-fitting engagement of the flat material without compression, and enabling easy removal of the bent part without clamping, using a design where the clear height can be increased post-bending to accommodate the material's expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the clear height of the circumferential groove is reduced to minimize material thickening, then the manufacturing precision improves, but the material may jam during bending
Solution Approach 1:
The bending mold is designed as a split mold with movable mold parts that allow dynamic adjustment of the clear height during the bending process. The clear height can be reduced during bending to minimize thickening and then increased after bending to prevent jamming, enabling the system to adapt to different process requirements
Solution Approach 2:
The invention changes the geometric parameter of the circumferential groove (clear height) during the bending process. By reducing the clear height during bending to minimize material thickening and then increasing it after bending to allow material expansion, the system optimizes both precision and reliability
2Reliability
If the clear height of the circumferential groove is increased to prevent material jamming, then the reliability improves, but material twisting and thickening increase
Solution Approach 1:
The split bending mold allows dynamic adjustment of the clear height - reduced during bending to prevent twisting and thickening, then increased after bending to accommodate material expansion and prevent jamming, resolving the contradiction between reliability and precision
3Device complexity
If a fixed clear height is used in the circumferential groove, then the device complexity is reduced, but the adaptability to different bending requirements decreases
Solution Approach 1:
The bending mold is divided into movable and fixed mold parts, allowing independent adjustment of the clear height. This segmentation enables the system to adapt to different bending requirements while maintaining a relatively simple overall structure
Solution Approach 2:
The movable mold parts enable dynamic adjustment of the clear height to match different bending requirements, providing adaptability without requiring a completely complex reconfigurable system
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution significantly reduces twisting and thickening issues, allowing for precise production of bent parts with small bending radii and short leg lengths, maintaining the insulation integrity of the material and preventing electrical breakdowns in insulated busbars.
Implementation Method 1
The section to be bent over is that section of the flat material whose orientation relative to a section not to be bent over is to be permanently changed by the bending operation by means of plastic deformation.
Implementation Method 2
The supplied flat material partially engages in the circumferential groove of the bending mold with that narrow side which is to form the inner contour of the bend after the bend.
Data Source
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AI summary
The invention relates to a bending machine for producing bent parts from flat material (190), comprising an intake device for taking in flat material from a material reserve having flat material, a bending device having a bending head for bending the flat material into a two or three-dimensional, bent part made of flat material; and a cutting device for separating the bent part from the flat material which has been taken in. According to the invention, the bending head has a bending form (400) having a circumferential groove (420) for receiving a section of the flat material (190) to be bent and a bending tool, which can rotate about the bending form, for engaging on a section of the flat material to be bent. According to the invention, the bending form (400) is designed as a divided bending form, which has a bottom form part (430) and a top form part (440), which is movable relative to the bottom form part, wherein a bottom boundary surface (422-1) of the circumferential groove is formed on the bottom form part and a top boundary surface (422-2) of the circumferential groove is formed on the top form part, and the top form part and the bottom form part are movable relative to each other in order to modify the clearance height (H) of the circumferential groove between a closed configuration, having a relatively low clearance height, and an opened configuration, having a greater clearance height compared to the lower clearance height.